Unit 4:

Mechanical Principles

Unit code:

F/601/1450

QCF level:

5
OUTCOME 3 POWER TRANSMISSION
TUTORIAL 2 - FRICTION CLUTCHES

3 Power Transmission
Belt drives: flat and v-section belts; limiting coefficient friction; limiting slack and
tight side tensions; initial tension requirements; maximum power transmitted
Friction clutches: flat single and multi-plate clutches; conical clutches; coefficient of
friction; spring force requirements; maximum power transmitted by constant wear and
constant pressure theories; validity of theories
Gear trains: simple, compound and epicycle gear trains; velocity ratios; torque, speed
and power relationships; efficiency; fixing torques

On completion of this short tutorial you should be able to do the following.

Describe a conical and a flat plate clutch.

Describe a multiplate clutch.

Explain the constant wear theory.

Explain the constant pressure theory.

Solve problems involving power transmission with clutches.

It is assumed that the student is already familiar with the following concepts.

Friction theory.
Angular motion.
Power transmission by a shaft.
Basic integral calculus.

All these above may be found in the pre-requisite tutorials.

D.J.DUNN freestudy.co.uk

CONTENTS
1.

Introduction

2.

Wear Theory

3.

Conical Clutches
3.1
Geometry
3.2
Uniform Pressure Theory
3.3
Uniform Wear Theory

4.

Flat Clutch Plates

4.1
Uniform Pressure Theory
4.2
Uniform Wear Theory
4.3
Multi-plate Clutches

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FRICTION CLUTCHES
1.

INTRODUCTION

First let's revise the basics of dry friction.

Consider a small block sliding over a surface.
The force pressing the two surfaces together is R (the normal force).
When the surfaces slip, the force F required to produce movement is
equal and opposite of the friction force between the surfaces. F and
R are related by Coulombs Law of Friction.
F = R

where is the coefficient of friction.

Figure 1
2.

WEAR THEORY

Research has shown that the wear between two rubbing surfaces depends upon the
pressure between the surfaces and the speed at which they rub.
There are two theories concerning the torque required to produce slip between the
surfaces of a clutch. One theory assumes the pressure is even over the surface of
contact in which case the wear is greater at the outside due to the greater velocity of
rubbing. The other theory assumes that the wear is uniform in which case the pressure
is not evenly distributed.
3.

CONICAL CLUTCHES
The picture shows a typical
conical clutch for larger power
transmission applications. There
are two cones covered in friction
material and when they are forced
apart they rub against the steel
outer casings and lock them
together thus engaging the two
halves.

Figure 2

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3.1

GEOMETRY

A conical clutch transmits rotation from one shaft to another through friction forces
on the conical face. The cone has a half angle of and the two halves are forced
together with a force R.

Figure 3
Consider an elementary ring on the face of the cone at radius r and radial width dr.

Figure 4
The length of the ring along the sloping surface is dr/sin. The area of the ring (dA) is
approximately the circumference (2r) times the width dr/sin.
2 rdr
dA
..............(1)
sin

D.J.DUNN freestudy.co.uk

3.2

UNIFORM PRESSURE THEORY

The force pressing the surfaces together produces a uniform pressure between them of
p N/m2. The force normal to the surface is R' and the force on the element is dR'
2 prdr
dR' p dA substituting equation (1) for dA we have dR'
sin
The total force R' acting on the conical area is given by integratin g.

R'

Do
2

Di
2

Do
2

Do

2 prdr 2 p
2 p r 2 2
p

rdr
D o2 D i2

sin
sin D
sin 2 D i 4sin
i

4R' sin

D o2 D i2

........................(2)

When the clutch slips, the friction force acting on the ring is dR'. This force
dr
produces a small torque dT rdR' 2p r 2
sin
The total torque is obtained by integrating between the inside and the outside.

2 p
sin

Do
2

r 2 dr

Di
2

2 p r 3

sin 3

Do
2

p 3
D o D 3i
12sin

Di
2

Substitute equation (2) for p

T

R' D 3o D 3i
3 D o2 D i2

In this derivation, R' is the total force acting normal to the surface. If this is resolved
to give the axial force R = R'sin and so
T

D.J.DUNN freestudy.co.uk

R D3o D3i
....................(3)
3sin D o2 Di2

3.3

UNIFORM WEAR THEORY

Consider the elementary ring again. dR' pdA

The velocity of any point is v m/s and the angular velocity is rad/s.
Uniform wear theory assumes that the wear is constant everywhere and it is directly
proportional to pressure x velocity (when slipping). Wear p v
Since v = r, then wear pr
For a constant , wear pr
p wear/r
The wear is constant so it follows that p = constant/r = c/r
As before the normal force is dR' pdA
Substitute equation (1) for dA
dr
c
dR' 2p r
and substituting p
sin
r
dr
dR' 2c
........................(4)
sin
Integrating between the inside and outside we get

2c
R'
sin

Do
2

Do

2c
c
dr sin r D2i sin (D o Di )
D
2

R' sin
...................(5)
(D o D i )

When the clutch slips, the friction force acting on the ring is dR'
This force produces a small torque of dT.
2c r dr
dT rdR ' and substituting equation (4) for dR ' we have dT
sin
Next we integrate.

2c
T
sin

Do
2

Di
2

2c r 2
rdr

sin 2

Equation (5) was c

Do
2

c 2
D o D i2
4sin

Di
2

R' sin
and substituting it in to the equation gives
(D o D i )

R' D o2 D i2 R' D o D i D o D i

4 (D o D i )
4
(D o D i )

R'
D o D i
4

D.J.DUNN freestudy.co.uk

Again, resolving R' to give the axial force R we get:

T

R
Do Di ................(6)
4sin

WORKED EXAMPLE No.1

A conical clutch has an included angle of 120o. The outer and inner diameters are
80 and 20 mm respectively. Calculate the force required to press the two halves
together if it is to transmit 200W at 600 rev/min. The coefficient of friction is 0.3.
Use both the uniform wear theory and the uniform pressure theory.
SOLUTION
Identify the variables and constants.
N = 600 rev/min = 120/2 = 60o. Do = 0.08 m Di = 0.02 m = 0.3
Power P = 200 W
UNIFORM PRESSURE

60P 60 x 200

3.1831 Nm
2 N
2 600

R D 3o D 3i
0.3R 0.083 0.023
T

3.1831
3sin D o2 D i2 3sin60 o 0.08 2 0.02 2
R

3.1831 x 3 x sin(60 o ) x 0.08 2 0.02 2

0.3 x 0.08 0.02

3

328.172 N

UNIFORM WEAR
R
D o Di
4sin
T x 4 sin(i 3.1832 x 4 x sin(60)
R

367.553 N
D o D i 0.3 x (0.08 0.02)

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SELF ASSESSMENT EXERCISE No.1

1.

The following data is for a conical clutch.

Inside diameter
Outside diameter
Coefficient of friction
Axial force
Included angle
Speed

30 mm
110 mm
0.23
800 N.
80o.
1000 rev/min

Calculate the torque and power that can be transmitted without slipping using
a) The uniform pressure theory. (11.11 Nm and 1163 W)
b) The uniform wear theory. (10.02 Nm and 1049 W)

2.

The following data is for a conical clutch.

Inside diameter
Outside diameter
Coefficient of friction
Included angle
Speed

20 mm
120 mm
0.3
100o.
3000 rev/min

Calculate the axial force needed to allow the transmission 800 watts without
slipping using
a)
The uniform pressure theory. (204.1 N)
b)
The uniform wear theory. (238.8)

D.J.DUNN freestudy.co.uk

4.

FLAT CLUTCH PLATES

The diagram shows a basic flat clutch. A disc with friction material is pressed against
a second disc thus engaging them by friction and making both discs rotate together.

Figure 5
A flat clutch is a special case of a conical clutch with an included angle of 180 o. It
may be idealised like this.

Figure 6
Consider a rotating shaft with a disc at the end that presses up against another so that
rotation is transmitted from one to the other by friction.
This is the special case of the cone clutch when = 90o and sin = 1. This produces
the results:
4.1

4.2

UNIFORM PRESSURE THEORY

R D3o D3i

3 D o2

Di2

per surface of contact

UNIFORM WEAR THEORY

R
Do Di per surface of contact
4

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4.3

MULTI-PLATE CLUTCHES

Figure 7
These are constructed with one set of plates attached to the inner shaft and the other
plates to the outer case. The plates are forced together with a mechanism. On the
diagram, there are five surfaces in contact and this allows a greater torque to be
transmitted before slip occurs. If there are n surfaces of contact then the maximum
torque is increased n times.
Values of pressure p vary from 350 kPa to 2800 kPa depending on the material. The
coefficient of friction is typically 0.25 for dry materials and 0.05 when immersed in
oil.

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10

WORKED EXAMPLE No.2

The following data is for a multiplayer clutch.
Number of
Contact surfaces. 5
Speed rev/min
2000
Outside diameter mm 150
Inside diameter mm
80
Coefficient of friction 0.25
Axial force R is 600 N

Calculate the maximum power that the clutch can transmit without slipping
based on constant wear theory.

Calculate the maximum power that the clutch can transmit without slipping
based on constant pressure theory.
SOLUTION
Identify the following
n=5
N=2000 rev/min
Do = 0.15 m
Di = 0.08 m
= 0.25
R = 600 N

Uniform Pressure
T

R D 3o D 3i
0.25 x 600 0.153 0.083
n
x 5 44.457 Nm
0.15 0.08
3 D o D i
3

2 NT 2 x 2000 x 44.457

9311 Watts
60
60
Uniform Wear
R
D o D i n 0.25 x 600 0.15 0.08 x 5 43.125 Nm
T
4
4
2 NT 2 x 2000 x 43.125
Power

9032 Watts
60
60
Power

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11

SELF ASSESSMENT EXERCISE No.2

1. A multi-plate clutch must transmit 20 kW of power without slipping at 4000
rev/min. The coefficient of friction is 0.28. The inner and outer diameters are 80
and 160 mm respectively. The axial force applied to the plates is 460 N.
Determine the number of plates required using:
i. The uniform pressure theory. (5.958 round up to 6)
ii. The uniform wear theory. (6.178 round up to 7)
2. A multi-plate clutch must has three contact surfaces and transmits power at 1500
rev/min. The coefficient of friction is 0.4. The inner and outer diameters are 30
and 150 mm respectively. The axial force applied to the plates is 400 N. Calculate
the torque and power that can be transmitted without slipping using:
i. The uniform pressure theory. (24.8 Nm and 3896 Watts)
ii. The uniform wear theory. (21.6 Nm and 3393 W)

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12